Micro Thin Film Sensor Embedding in Metals by Ultrasonic Welding for Production of Miniature Smart Tooling

This work is to study micro thin film sensor embedding in metals for the production of miniature smart tooling. This technique promises to significantly improve the safety and reliability for manufacturing processes and reduce operation costs. One key concern of the current research is to investigate if sensor functionality can be maintained during and after embedding in metals by use of ultrasonic welding (USW), which could be hostile to micro thin film thermocouples (TFTCs) embedded near the welding interface. The welding workpieces, consisting of a nickel strip with embedded micro sensors and a copper thin sheet, were welded by USW process. Experimental results showed that TFTCs survived the ultrasonic welding process. The embedded TCFCs were also capable of measuring temperature in-situ near the weld interface during the embedding process.

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Ammonia gas sensing with tin oxide thin film sensor and coplanar microheater

10.1063/5.0031525 ◽

2020 ◽

Author(s):

Shobi Bagga ◽

Jamil Akhtar ◽

Sanjeev Mishra

Keyword(s):

Thin Film ◽

Tin Oxide ◽

Gas Sensing ◽

Oxide Thin Film ◽

Film Sensor ◽

Ammonia Gas ◽

Thin Film Sensor

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Metal oxide semiconductor based thin film sensor for nitro aromatic explosive detection

International Conference for Convergence for Technology-2014 ◽

10.1109/i2ct.2014.7092345 ◽

2014 ◽

Cited By ~ 1

Author(s):

Mathure Sagar ◽

Rohini Mudhalwadkar ◽

Gaurav Sonar

Keyword(s):

Thin Film ◽

Metal Oxide ◽

Metal Oxide Semiconductor ◽

Oxide Semiconductor ◽

Explosive Detection ◽

Film Sensor ◽

Thin Film Sensor ◽

Nitro Aromatic

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STUDY OF DNA-DIETHYLSTILBOESTROL INTERACTION USING GRAPHENE-BASED THIN-FILM SENSOR AND UV-VIS SPECTROSCOPY

Journal of the Chilean Chemical Society ◽

10.4067/s0717-97072018000103795 ◽

2018 ◽

Vol 63 (1) ◽

pp. 3795-3798

Author(s):

Meifeng Chen ◽

Xinying Ma ◽

Xia Li ◽

Mingjing Yin ◽

Yanyun Li ◽

...

Keyword(s):

Thin Film ◽

Film Sensor ◽

Thin Film Sensor ◽

Vis Spectroscopy

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A simple and cost-effective zinc oxide thin film sensor for propane gas detection

Materials Letters ◽

10.1016/j.matlet.2015.05.065 ◽

2015 ◽

Vol 157 ◽

pp. 169-171 ◽

Cited By ~ 37

Author(s):

Vinoth Kumar Jayaraman ◽

Arturo Maldonado Álvarez ◽

María de la Luz Olvera Amador

Keyword(s):

Thin Film ◽

Zinc Oxide ◽

Cost Effective ◽

Gas Detection ◽

Oxide Thin Film ◽

Zinc Oxide Thin Film ◽

Film Sensor ◽

Thin Film Sensor

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Transient Temperature and Heat Flux Measurement in Ultrasonic Joining of Battery Tabs Using Thin-Film Microsensors

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4024816 ◽

2013 ◽

Vol 135 (5) ◽

Cited By ~ 30

Author(s):

Hang Li ◽

Hongseok Choi ◽

Chao Ma ◽

Jingzhou Zhao ◽

Hongrui Jiang ◽

...

Keyword(s):

Thin Film ◽

Heat Flux ◽

Heat Generation ◽

Welding Process ◽

Ultrasonic Welding ◽

Transient Temperature ◽

Monitoring And Control ◽

Change Rate ◽

Flux Change ◽

And Control

Process physics understanding, real time monitoring, and control of various manufacturing processes, such as battery manufacturing, are crucial for product quality assurance. While ultrasonic welding has been used for joining batteries in electric vehicles (EVs), the welding physics, and process attributes, such as the heat generation and heat flow during the joining process, is still not well understood leading to time-consuming trial-and-error based process optimization. This study is to investigate thermal phenomena (i.e., transient temperature and heat flux) by using micro thin-film thermocouples (TFTC) and thin-film thermopile (TFTP) arrays (referred to as microsensors in this paper) at the very vicinity of the ultrasonic welding spot during joining of three-layered battery tabs and Cu buss bars (i.e., battery interconnect) as in General Motors's (GM) Chevy Volt. Microsensors were first fabricated on the buss bars. A series of experiments were then conducted to investigate the dynamic heat generation during the welding process. Experimental results showed that TFTCs enabled the sensing of transient temperatures with much higher spatial and temporal resolutions than conventional thermocouples. It was further found that the TFTPs were more sensitive to the transient heat generation process during welding than TFTCs. More significantly, the heat flux change rate was found to be able to provide better insight for the process. It provided evidence indicating that the ultrasonic welding process involves three distinct stages, i.e., friction heating, plastic work, and diffusion bonding stages. The heat flux change rate thus has significant potential to identify the in-situ welding quality, in the context of welding process monitoring, and control of ultrasonic welding process. The weld samples were examined using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) to study the material interactions at the bonding interface as a function of weld time and have successfully validated the proposed three-stage welding theory.

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